Support for radiant covering and floor heating elements

ABSTRACT

A floor support includes a base having a bottom surface and a top surface; a plurality of bosses arranged in an ordered array on the base, the ordered array configured to provide multiple options for routing an electric heating cable among the plurality of bosses; and a thermal insulation layer adjacent the bottom surface. Each of the plurality of bosses includes an upper surface; a perimeter wall extending from the upper surface to the top surface, the perimeter wall sloping underneath the upper surface; and an interior wall sloping continuously toward an interior of the boss as the interior wall as the interior wall extends from the upper surface to the top surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 15/647,510, filed on Jul. 12, 2017, which is a continuation of U.S. patent application Ser. No. 15/185,576, filed on Jun. 17, 2016, now U.S. Pat. No. 9,726,383, which claims the benefit of Italian Patent Application No. 102016000033439 filed Apr. 1, 2016, and Registered Community Design Application Nos. 003067388-0001, 003067388-0002, 003067388-0003 and 003067388-0004, filed with the European Union Intellectual Property Office on Apr. 13, 2016, the entire contents of all of which are incorporated herein by reference in their entirety.

SUMMARY

This disclosure refers to a support (10) for the heating elements of radiant coverings and floors, comprising a base (11) from which bosses develop (12, 13, 14, 15) defining interspaces (16, 17, 18, 19) between them for laying pipes or electric heating cables, which is characterized by the fact that each of these bosses has a concave portion (20), with concavity facing outwards in a laying position, on the surface (21) of said concave portion (20) as at least one adhering low relief is defined (22, 23, 24, 25), in turn defining an anti-extraction undercut (22 b) to be filled with material for laying a covering element.

DESCRIPTION

This disclosure relates to a support for the heating elements of radiant coverings and floors.

Nowadays are known and widespread support structures for the heating elements of radiant coverings and floors, with hydraulic or electric type heating elements, generally comprising a base, often consisting of a panel or sheet or flexible thermoplastic membrane, from which an ordered array of bosses develop defining between them interspaces for laying heating pipes or electric cables.

The bosses have perimeter walls with anti-extraction template for the interlocking of a pipe or cable in the space between the two adjacent bosses.

The bosses, usually in a single body with base, have a cavity, open towards the outside in position for use, intended to be filled with adhesive material used for laying the overlying tiles or natural stones.

Said bosses with cavity, although widespread and appreciated, have an important limit due to the fact that the adhesive, once dried, mechanically adheres in the interspaces between the bosses thanks to the undercut portions defined by the anti-extraction template of the bosses' walls, whereas the gripping inside their cavities is milder because such cavities are concave and there are no parts where the dry adhesive can be laid taking an anti-extraction shape with mechanical gripping.

Another known limit of these panels and membranes is constituted by the fact that the base from which the bosses develop is generally a flat sheet, below which is trapped the steam which the heat developed from the radiant elements lets out from the underlying screed; the trapped steam can generate swelling and areas with risk of detaching for the panel with bosses and for the overlying covering.

The task of this disclosure is to create a support for heating elements for radiant coverings and floors able to obviate the limits of the known panels and membranes.

Within this task, an aim of the disclosure is to set-up a support suitable for mechanical adhesion with the material for laying covering with respect to the known panels and membranes.

Another aim of the disclosure is that to set-up a support which cooperates in preventing the formation of bulges between the support itself and the underlying screed, due to the evaporated and trapped steam.

A further aim of the disclosure is that to set-up a support which can be used for the construction of radiant coverings and floors in the same way of the known support panels.

This task, as well as these and other aims hereinafter, are achieved by a support for the heating elements of radiant coverings and floors, according to declaration 1.

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the disclosure will be clearer from the description of three forms of preferred executions, but not exclusive, of the support according to the disclosure, illustrated as an example but not limited to, in the attached drawings, in which:

FIG. 1 shows a perspective view of a portion of a support according to the disclosure in its first embodiment;

FIG. 2 represents a cross-section of a support according to the disclosure in FIG. 1;

FIG. 2a represents a detail of FIG. 2;

FIG. 3 represents a bottom view of the portion of FIG. 1;

FIG. 4 shows a perspective view of a portion of a support according to the disclosure in its second embodiment;

FIG. 5 represents a crossway section of a support as per FIG. 4;

FIG. 5a represents a detail of FIG. 5;

FIG. 6 represents a perspective view of a portion of a support according to the disclosure in its third embodiment;

FIG. 7 represents an additional perspective view of a portion of a support according to the disclosure in its third embodiment;

FIG. 8 represents a side view of the support portion of FIG. 6.

DETAILED DESCRIPTION

With reference to FIGS. 1-8, a support according to the disclosure is generally indicated in embodiments, with the number 10.

This support 10 for heating element of radiant coverings and floors includes a base 11 from which the bosses develop, for example 12, 13, 14, 15 in FIG. 1, for example, but not exclusively, arranged according to an ordered array, defining interspaces 16, 17, 18, 19 between them for laying pipes or electric heating cables, the latter not shown for simplicity.

In some embodiments, base 11 is flat or substantially planar.

Base 11 and bosses 12, 13, 14 and 15 may be formed as a single plastic body and a polypropylene or polyethylene membrane (or of other thermoplastic material) which allows venting the steam from an underlying support surface on which it is laid and at the same time waterproof, that is the membrane helps prevent the passage of water towards the same support surface. The base 11 and bosses 12, 13, 14, and 15 may also be formed as a plastic panel.

In some embodiments, the bosses have perimeter walls, for example 12 a and 13 a in FIG. 2, with an anti-extraction template for the interlocking of a heating cable in interspace 16 between two adjacent bosses, for example bosses 12 and 13. Also in some embodiments, the bosses have a substantially planar upper surface 40 separated into two portions 40 a and 40 b by a raised ring 38. The raised ring 38, which is surrounded by the portion 40 a of the upper surface 40 and which surrounds the portion 40 b of the upper surface 40, extends from the upper surface 40 and away from the base 11. The perimeter walls 12 a and 13 a slope underneath the upper surface 40, and more particularly underneath the upper surface portion 40 a.

One aspect of the present disclosure resides in the fact that each of said bosses 12, 13, 14 and 15 are provided with a concave portion, for example portion 20 for the first boss 12 and portion 26 for the second boss 13, with the concavity facing the outside in a laying position (e.g., facing upward and away from a floor on which the base 11 is resting).

Defined on the surface 21 of said concave portion 20 is at least one adhering low relief, for example four adhering low reliefs 22, 23, 24, 25 may be provided per concave portion 20. Some or all of the bosses 12, 13, 14, and 15 may be provided with respective concave portions 20 having a number of low reliefs. For instance, boss 13 is shown to include reliefs 22 a, 23 a, 24 a, and 25 a.

Each of these adhering low reliefs 22, 23, 24 and 25 defines, in turn, an anti-extraction undercut, for example 22 b detailed in FIG. 2a , to be filled with material for laying a coating element (e.g., a tile adhesive material) which fills the same concave portion 20 and 26 as well as the interspaces 16, 17, 18, and 19.

The anti-extraction undercut 22 b is to be understood such with respect to a plane P parallel to base 11 and passing through an upper point 22 c of the outer edge of the corresponding low relief 22.

Said anti-extraction undercut 22 b prevents the extraction of the filling material, which fills concave portion 20, and also fills the low relief 22, in a Y direction orthogonal to plane P, thus improving the adhesion of the same material, and of the overlying covering, to support 10.

The low reliefs of the second boss 12 are shown, as an example, with 22 a, 23 a and 24 a.

In the embodiment of FIGS. 1 and 2, each adhering low relief 22, 23, 24, 25 is cylindrical with the main X axis orthogonal to surface 21 of the corresponding concave portion 20, with rounded inner corners to help the extraction of the equipment with which the bosses are moulded on the base.

In another embodiment, indicated with 110 and represented in FIGS. 4 and 5, for each boss 112 and 113 each adhering low relief 122, 123, 124, 125 has a semicylindrical template in cross-section, with main axis Z parallel to surface 121 of the concave portion 120.

Each of these adhering low reliefs 122, 123, 124 and 125 defines in turn an anti-extraction undercut, for example 124 b detailed in FIG. 5a , to be filled with material for laying a coating element (e.g., a tile adhesive material) which fills the same concave portion 120 and 126 as well as the interspaces.

The anti-extraction undercut 124 b is to be understood such with respect to a plane P parallel to base 111 and passing through the upper outer edge 124 c of the corresponding low relief 124.

This anti-extraction undercut 124 b prevents the extraction of the filling material, which fills the concave portion 120, thus also the low relief 124, in a Y direction orthogonal to plane P.

These adhering low reliefs can also have other shapes (e.g., in cross-section or in other dimensions), for example with a semispherical, triangular, square, rhomboidal, oval section and other shapes, templates and profiles, depending on the technical needs and requirements.

In these example embodiments, not restrictive of the disclosure, each concavity has a truncated conical shaped surface 21, with walls 30, 31, 32, 33 connected by curved sections.

Support 10 includes at least one low relief 22, 23, 24, 25 for each of the said walls 30, 31, 32, 33, for example one low relief for each wall, as in FIGS. 1 and 3.

In another embodiment of the disclosure, clearly visible in FIGS. 6 to 8 and indicated therein with number 210, in correspondence of said interspaces, on said base 211, are channels 240, 241, 242, 243 to convey the steam towards the collection chambers 244, 245 defined between the body of said bosses 212, 213, 214, 215 and an underlying surface, such as the screed, an adhesive layer or another layer fixed to base 211 of the same support 210.

These channels 240, 241, 242, 243 are closed on top but are open towards the surface to which support 210 is fixed and communicate with the collection chambers 244 and 245 through corresponding passages, such as 246, 247, 248 and 249 in FIGS. 7 and 8.

Thanks to the bosses having flat and/or walls and the chambers 244 and 245 defined inside each boss, and to the conveying channels, it is possible to collect at least part of the steam possibly coming out from the screed due to the heat given off by the heating elements laid on support 210, and avoid that this steam determines the formation of bulging areas and the detachment of the same support 210 from the underlying screed or other support surface and fixing.

The support according to the disclosure, in its three embodiments above 10, 110 and 210, may also include a thermal insulation layer 50 located under the base 11, 111, 211 and developed to involve the entire base 11, 111, 211 including the areas in which said bosses 12, 13, 14, 15, 112, 113, 212, 213, 214, 215 develop.

Said thermal insulation layer 50 may be made of fabric (including woven or non-woven fabric) or cork or a metal sheet or other similar and equivalent materials. For example, the thermal insulation layer 50 may comprise aluminum foil, polystyrene, wool, and/or fleece.

Basically, it has been ascertained how the disclosures achieves the intended task and purposes.

In particular, with the disclosure we have developed a support which is optimal for mechanical adhesion with the adhesive material for laying the coverings with respect to the known panels.

In addition, with the disclosure a support has been set-up which cooperates in preventing the formation of bulges between the support and the underlying screed, due to the evaporated and trapped steam.

Furthermore, with the disclosure we have developed a support which is simple and intuitive to use.

In addition, with the disclosure we have developed a support that can be used for the realization of radiant floors in the same way as the known support structures.

The disclosure, thus conceived, is susceptible of various changes and variations, all falling within the inventive concept; moreover, all details can be replaced with others technically equivalent.

Basically, the used components and materials, as long as compatible with the specific use, as well as the contingent shapes and dimensions, can be any according to the requirements and state of the art.

Where the features and techniques mentioned in any claim are followed by benchmarks, these marks are affixed with the sole purpose of increasing the intelligibility of the claims and such benchmarks have no limiting effect on the interpretation of each element identified by way of example by such benchmarks. 

What is claimed is:
 1. A floor support comprising: a base having a bottom surface and a top surface; a plurality of bosses arranged in an ordered array on the base, the ordered array configured to provide multiple options for routing an electric heating cable among the plurality of bosses, wherein each of the plurality of bosses comprises: an upper surface; a perimeter wall extending from the upper surface to the top surface, the perimeter wall sloping underneath the upper surface; and an interior wall sloping continuously toward an interior of the boss as the interior wall extends from the upper surface to the top surface, the interior wall comprising an adhering low relief with an anti-extraction undercut; and a thermal insulation layer adjacent the bottom surface.
 2. The floor support of claim 1, wherein the thermal insulation layer is made of fabric.
 3. The floor support of claim 2, wherein the fabric is a non-woven fabric.
 4. The floor support of claim 2, wherein the fabric is wool.
 5. The floor support of claim 2, wherein the fabric is fleece.
 6. The floor support of claim 1, wherein the thermal insulation layer comprises a metal sheet.
 7. The floor support of claim 6, wherein the metal sheet is aluminium foil.
 8. The floor support of claim 1, wherein the thermal insulation layer comprises polystyrene.
 9. A support for heating elements, comprising: a thermoplastic body comprising: a plurality of planar base portions, each of the planar base portions comprising a top side and a bottom side; a plurality of bosses extending above the plurality of planar base portions, each of the plurality of bosses comprising: an upper surface; a perimeter wall extending from the upper surface to the top side of a first one of the plurality of planar base portions, the perimeter wall sloping underneath the upper surface; and an interior wall sloping continuously toward an interior of the boss as the interior wall extends from the upper surface to the top side of a second one of the plurality of planar base portions, the interior wall comprising an adhering low relief with an anti-extraction undercut; and a thermal insulation layer adjacent the bottom side of the plurality of planar base portions.
 10. The support of claim 9, wherein the thermal insulation layer comprises fabric.
 11. The support of claim 10, wherein the fabric is a non-woven fabric.
 12. The support of claim 10, wherein the fabric is wool.
 13. The support of claim 10, wherein the fabric is fleece.
 14. The support of claim 9, wherein the thermal insulation layer comprises a metal sheet.
 15. The support of claim 14, wherein the metal sheet is aluminium foil.
 16. The support of claim 9, wherein the thermal insulation layer comprises polystyrene.
 17. A heating element support comprising: a thermoplastic body comprising: a plurality of planar base portions, each of the planar base portions comprising a top side and a bottom side; a plurality of bosses extending to a first height above the plurality of planar base portions, each of the plurality of bosses comprising: a substantially planar upper surface; a perimeter wall extending from the upper surface to the top side of a first one of the plurality of planar base portions, the perimeter wall sloping underneath the upper surface; and an interior wall sloping continuously toward an interior of the boss as the interior wall extends from the upper surface to the top side of a second one of the plurality of planar base portions; and a plurality of channels having a closed top and extending to a second height above the plurality of planar base portions, the second height lower than the first height; and a thermal insulation layer adjacent the bottom side of the plurality of planar base portions, the thermal insulation layer comprising a non-woven fabric.
 18. The heating element support of claim 17, wherein the interior wall of each of the plurality of bosses comprises a plurality of undercuts, each of the plurality of undercuts extending underneath at least a portion of the interior wall.
 19. The heating element support of claim 17, further comprising a raised ring extending upwardly from the substantially planar upper surface, the raised ring surrounded by a first portion of the upper surface and surrounding a second portion of the upper surface.
 20. The heating element support of claim 17, wherein the non-woven fabric is fleece. 